Bevel Box Output Flange Seal, Bevel Box Removed
Bevel Box Output Flange Seal, Bevel Box Removed
Special tools, testers and auxiliary items required
• Holding Fixture (VW 313)
• Tube 42 mm Dia. (VW 516)
• Thrust Piece (40-105)
• Thrust Piece (T10049)
• Gearbox Support (T10108)
• Stop Plate (T10108/1)
• Tapered Roller Bearing Puller (V.A.G 1582) with short sleeve
• Only for seal in pinion housing, refer to => [ Output Flange seal in Pinion Housing,
Removing and Installing: ]
• Attachment to V.A.G 1582 (V.A.G 1582/6) or grip (V.A.G 1582/6A)
• 2-Arm Puller Kukko (20/10)
• Only for seal on the output flange, refer to => [ Output Flange Seal Removing and Installing: ]
• Adapter (V.A.G 1582/13)
• Continuation for all
• Torque Wrench (V.A.G 1601)
• Kukko Three-Arm Puller (45-2)
• Only for seal in pinion housing, refer to => [ Output Flange seal in Pinion Housing,
Removing and Installing: ]
• Slide Hammer-Complete Set (VW 771)
• Only for seal in pinion housing, refer to => [ Output Flange seal in Pinion Housing,
Removing and Installing: ]
• Additional Part for VW 771 (VW 771/37)
• Only for the seal on the output flange, refer to => [ Output Flange Seal Removing and Installing: ]
• Thrust Disc (VW 412)
• Thrust Tube (VW 454)
• Thrust Tube (VW 455)
• Thrust Plate (VW 401)
• Two M8 x 30 mm stud bolts or Guide Pins M8 (T10273)
• Bolt (VW 460/2)
Continuation for all
Sealing grease (G 052 128 A1)
2 bolts M 10 x 30
2 nuts M 12 x 10
• Bevel box output flange seal can only be replaced with bevel box removed.
• Inner race/tapered roller bearing is located in the output flange bevel box.
• These will be removed later in the procedure.
• Do not replace the tapered roller bearing for the output flange bevel box and the shim!
- Mount the bevel gear on the hole marked with the number - 4 - - arrow - in the (T10108).
A Insert nut M 12 x 10 (quantity: 4) between bevel box and transmission holder.
- Then align bevel box to the remaining 3 holes and secure.
- Place a drip tray underneath.
- Drain the gear oil out of the bevel box.
- Lock the bevel box output flange in place with stop plate (T10108/1). Use M10 x 30 bolts - arrows - to lock the flange.
Remove Hex Nut for Output Flange.
A 36 mm socket for 3/4 inch drive
- Pivot bevel box so that output shaft faces upward.
- Remove the output flange and bearing inner race/tapered roller bearing from the bevel box shaft bevel gear.
A Kukko Three-arm puller , for example, (45-2)
- Please note the different installation locations for the output flange seals:
The Output Flange Seal - arrow - is inside the Pinion Housing.
Output flange seal in pinion housing, removing and installing, refer to => [ Output Flange seal in Pinion Housing,
Removing and Installing: ].
The Seal - arrow - is Found on the Output Flange.
Output flange seal, removing and installing, refer to => [ Output Flange Seal Removing and Installing: ].
Output Flange seal in Pinion Housing, Removing and Installing:
Seal, Removing
- Remove output shaft seal - A -.
• Remove bearing inner race/tapered roller bearing from the output flange:
- Place the (40-105) on the output flange.
- Remove the bearing inner race/tapered roller bearing from output flange with tapered roller bearing puller.
• Attachment to VAG1582 (V.A.G 1582/6A) can be used in place of attachment to VAG1582 (V.A.G 1582/6).
Install Seal and Output Flange.
- Cover pinion housing with a lint-free cloth.
- Clean any remaining locking fluid from the thread on the shaft bevel gear.
• If the shim - 2 - is removed during the removal of the output flange, place it back in the pinion housing.
• This will maintain the bearing preload on the shaft bevel gear - 1 - inside the pinion housing.
- Place the old bearing inner race/tapered roller bearing - 3 - into the outer race inside the bevel box.
- Lightly lubricate the outer circumference of the new output flange sealing ring - 4 -.
- Install the new seal using the (T10049).
• The seal must be flush with the upper edge of the housing.
- Fill the space between the sealing and dust lip half way with sealing grease (G 052 128 A1).
- Install the output flange using the two-arm puller - A -.
A 2-Arm puller Kukko , for example, (20/10)
Note the following:
• Use a new removal hook.
• To not tilt the output flange.
• Mount the hooks on the bottom of the pinion housing.
• Tension the removal hook with the two-arm puller - arrows -.
• Do not bend the removal hook toward the outside.
• Interrupt the procedure if necessary, remove the output flange again and repeat the process.
Output Flange Seal - arrow - Removing and Installing:
Seal, Removing
• When removing the output flange seal, the bearing inner race/tapered roller bearing must also be removed.
- Place the (40-105) on the output flange.
- Remove the bearing inner race/tapered roller bearing from output flange with tapered roller bearing puller.
- Remove the output flange seal.
Seal, Installing
• First remove the pinion housing - 1 - along with the shaft bevel gear - 2 - in order to install the seal:
- Remove the bolts for the pinion housing - 1 -; and carefully remove the pinion housing diagonally of the protruding edges.
- Remove the pinion housing and the shaft bevel gear - 2 -.
- Clean the thread on the shaft bevel gear.
• If the shim - 3 - is removed during the removal of the output flange, place it back in the pinion housing.
• This will maintain the bearing preload on the shaft bevel gears inside the pinion housing.
- Place the old bearing inner race/tapered roller bearing - 1 - into the pinion housing.
- Lightly lubricate the outer circumference of the new output flange sealing ring - 2 -.
- Install the new seal using the (T10049).
• The seal must be flush with the upper edge of the housing.
- Fill the space between the sealing lip and dust lip halfway with sealing grease (G 052 128 A1).
- Press in the output flange along with the pinion housing and shaft bevel gear all the way.
• The shoulder - arrow - of the (VW 455) faces the shaft bevel gear.
- Install the stud bolts M8 X 30 mm = - A - or (T10273) into the drive axle housing.
- Slide a new O-ring - 1 - onto the pinion housing - 2 -.
The pinion housing - 2 - and shim - 3 - only fit one way.
- Install the previous shim - 3 -.
- Carefully install the pinion housing diagonally all the way with bolts (VW 460/2).
There is very little space between the pinion housing and the bevel box housing.
The gap is closed when the pinion housing is tightened.
- Tighten the bolts for the pinion housing - 2 - diagonally.
Continuation for All
Coat Threads of New Hex Head Nut with Locking Compound D 000 600.
- Tighten new output flange hex head nut.
A 36 mm socket for 3/4 inch drive
- Check axle oil in the bevel box. Refer to => [ Axle Oil in Bevel Box, Checking or Filling ] Procedures.